IS 15201: Hydrogen--Code of Safety

12 Pages·2002·1.3 MB·English

by  Bureau of Indian Standards (BIS)

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IS 15201 (2002): Hydrogen--Code of Safety. ICS 13.200 :
11.100.20
“!ान $ एक न’ भारत का +नम-ण”
Satyanarayan Gangaram Pitroda
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“Knowledge is such a treasure which cannot be stolen”

IS 15201 : 2002
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Indian Standard
HYDROGEN - CODE OF SAFETY
ICS 13.300;11.100.20
© BIS 2002
BUREAU OF INDIAN STANDARDS
MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002
Septemher 2002 Price Group 4
Industrial Safcty and Chemical Hazards Sectional Committee, CHD 8
FOREWORD
This Indian Standard was adopted by the Bureau of Indian Standards, after the draft finalized by the Industrial
Saldy and Chemical Hazards Sectional Committee had been approved by the Chemical Division Council.
Hydrogen is lIsed ill the hydrogenation of edible and petroleum oils, in the synthesis of ammonia, methanol,
hydrochloric acid, aluminium alkyls, higher alcohols and aldehydes, in the reduction of metal oxides (such as iron
ore) and in \velding. Liquid hydrogen is an important cI)'ogenic fluid.
llydrogen is a highly flammable liquid or gas and has a dangerous fire and explosion hazard. Exposure to high
levels of hydrogen gas concentration can cause suffocation for lack of oxygen. Contact with liquid hydrogen can
causc frostbitc.
There is no ISO Standard on this subject. In the preparation of this Code, considerable assistance has been derived
from the following Pllblications:
a) Sax's Dangerous Properties of Industrial Materials, Volume No.3, 10th edition, Wiley-Interscience
Publication. John Wiley and Sons. Inc., 2000.
b) Recommendations on the Transport of Dangerous Goods, 9th revised edition, United Nations, Geneva,
1995.
c) Material Safety Data Sheets, Phase-I, by Indian Chemical Manufacturers Association, 1991.
d) Handbook of Toxic and Hazardous Chemicals and Carcinogens, Volume II, 3rd edition, Marshall Sittig,
Noyes Publications, Park Ridge, New Jersey, USA, 1991.
c) Chemical Safety Data Sheets, Flammable Chemicals, Volume 5, Royal Society of Chemistry, United
Kingdom, 1992.
f) Hydrogen: Production and Marketing, W. N. Smith, 1. G. Santangel, ACS Symposium series 116, 1980.
g) Encyclopedia of Chemistry, S. P. P(]rker, McGraw Hill, 1982.
11) Gaseous Hydrogen Stations, Industrial Gases Committee, 32 Boulevard de la Chapel1e, 75880, Paris,
Ccdex IX, France, September 1980.
The composition of the Committee responsible for formulation of this standard is given in Annex A.
IS 15201 : 2002
Indian Standard
HYDROGEN-CODE OF SAFETY
1 SCOPE 4.1.4 UN Number
1.1 This code prescribes physical and chemical 1049 for gas (hydrogen, compressed), and
.
properties of hydrogen gas, the nature of hazards 1966 for liquid (refrigerated liquid).
associated with it, preventive measures for controlling
the hazards, and essential information on storage, 4.1.5 CAS Number
handling, labelling, transportation, waste disposal,
1333-74-0
training of personnel, personal protective equipment,
first aid and fire fighting. 4.1.6 Class
1.2 This code does not, however, deal with any 2 (flammable gas).
specification for design of buildings, chemical
4.1.1 Molecular Mass
engineering plants, mcthcxl and ingredients used in the
manufacture, equipment for waste disposal and 2.01594.
operation control.
4.2 Physi~al Properties
2 REFERENCES
4.2.1 Description
The Indian Standards listed below contain provisions
Colourless, odourless and tasteless gas.
which through reference in this 'text, constitute
provisions ofthis standard. At the time of publication, 4.2.2 Boiling Point
the editions indicated were valid. All standards are
(-) 252.8°C.
subject to revisions, and parties to agreements based
on this standard are encouraged to investigate the 4.2.3 Melting Point
possibility of applying the most recent editions of the
(-) 259.2°C.
standards:
IS No. Title 4.2.4 Vapour DenSity (Air = J)
4155: 1966 Glossary of terms relating to 0.069.
chemical and radiation hazards and
4.2.5 Density, gil
hazardous chemicals
4379: 1981 Identification of contents of 0.0899.
industrial gas cylinders (first
4.2.6 Vapour Pressure (Hg in mm)
revision)
1 570 at -250°C.
3 TERMINOLOGY
4.2.7 Solubility
For the purpose of this standard, the definitions given
in IS 4155 shall apply. Slightly soluble in alcohol and ether. 1.82 percent
soluble in water at 20°C.
4 GENERAL INFORMATION AND
PROPERTIES 4.3 Chemical Properties
4.3.1 Reactivity
4.1 General Information
Hydrogen is stable under normal temperature and
4.1.1 Chemical Name
pressure. Violent reaction or ignitio~ takes place with
Hydrogen. air in presence of catalyst like platinum and similar
metals containing absorbed oxygen or hydrogen,
4.1.2 Common Name bromine, iodine, dioxane + nickel. lithium, nitrogen
trifluoride, nickel + oxygen, oxygen difluoride.
Liquid hydrogen, para hydrogen, hydrogen
(compressed), dihydrogen. 4.4 Fire and Explosion Hazard Properties
4.1.3 Alolecular Formula 4.4.1 Auto Ignition Temperature
IS 15201 : 2002
4.4.2 Flash Point on before work. Curness trousers should be worn
outside boots or over high top shoes to shed spilled
Not pertinent.
liquid.
4.4.3 F'lammahility
6.3 Respiratory E(luiJlment
4.4.3.1 Explosive limits with air, percent(v/v) Hydrogen is a simple asphyxiant. It can replace oxygen
a) Upper explosive limit (UEL) 74.2 and lead to suffocation. An approved self-contained
breathing apparatus with a full facepiece operated in
b) Lower explosive limit (LEL) 4.0
positive pressure mode should be used in oxygen
4.5 Corrosion Properties deficient environments.
Not corrOSIve. 7 STORAGE, HANDLING, LABELLING AND
TRANSPORT
5 TOXICITY INFORMATION AND HEALTH
EFFECTS 7.1 Storage
5.1 Toxicity 7.1.1 General Precautions
Hydrogcn is not toxic except that it may asphyxiate. It 7.1.1.1 Hydrogen must be stored to avoid contact with
may displace the oxygen in a workplace atmosphere heat. flames, sparks and oxygen. Sources of ignition
and thus act as an asphyxiant. such as smoking and open flames are prohibited where
hydrogen is used, handled or stored.
5.2 Routcs of Entry
7.1.1.2 Metal containers involving transfer of large
Skin and inhalation. quantities of hydrogen should be grounded and bonded.
Piping should be electrically bonded and grounded.
5.3 Health Effects
7.1.1.3 Containers must be equipped with self-closing
5.3.1 Contact (~f Liquid Hydrogen with Skin
valves, pressure vacuum bungs and flame arrestors.
Dircct cont.act of body tissue with liquid hydrogen can
7.1.1.4 Only non-sparking tools and equipment,
cause cold burns or frost bite.
especially when opening and closing containers of
5.3.2 Asphyxiation ,hydrogen should be used.
Hydrogcn displaces the oxygen in the workplace 7.1.1.5 Whe'rever hydrogen is used (handled,
atmosphere. If atmosphere does not contain enough manufactured or stored), approved explosion-proof
oxygen then inhalation can cause dizziness, un;. electrical equipment and fittings should be used.
consciollsness or even death.
7.1.1.6 Automatic or manual shutdown processes,
,i PERSONAL PROTECTIVE EQUIPMENT sprinklers, gas and heat sensors with early waming
audio-visual alarms, flooding, water spraying,
6.1 Genc.·a) extinguishing systems, explosion relief devices should
be available in storage areas.
Personal protective equipment is not an adequate
substitute for good, safe working conditions, adequate 7.1.1.7 The building shall have good low and high
ventilation and intelligent conduct on the part of the level natural ventilation. In areas where natural
cmployees. One should keep firmly in mind that ventilation is not possible, forced ventilation equip
personal protective equipment protects only the person ments should be installed.
wearing it and other unprotected workers in the area
lIlay be exposed to danger. 7.1.2 Indoor Storage
(1.2 No n-Rcspi ratory E(luipment 7.1.2.1 Avoid mechanical damage or overheating of
storage tanks and cylinders.
Personal protecting equipment should include non
respiratory equipment like splash-proof safety goggles 7.1.2.2 The vents from the storage tanks, relief valve
and face shield when working with liquid, unless full must be led to a safe location to avoid any explosions
facepicce respiratory protection is worn for eye with suitable flame arrestors fitted in it.
protection, safety helmets for head protection and boots
7.1.3 Outdoor Storage
or high top shoes for foot protection. Where exposure
to cold cquipment, va pours, or liquid may occur, 7.1.3.1 Outside storage tanks may be located at least
cmployees should wear special clothing designed to 15 metres away from building or adjacent to blank
prcvcnt the freezing of body tissues. All protective masonry building walls. The location should be away
clothing (suits, shirts with long sleeves, insulated from any flammable liquid storage with adequate
gloves) should be clean, available each day, and put approved fire protection system.
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IS 15201 : 2002
7.1.3.2 Cylinders must be protected from direct sun 7.2.2.5 While handling by crane or derrick, a suitable
rays. Provision of shed should be done for outdoor platfonn, cradle or boat should be used. Use rack or
storage of cylinders. chain to hold cylinders in place when hooked up for
discharging.
7.1.4 Bulk Storage (Non-refrigerated)
7.2.2.6 Do not place or handle cylinders where they
7.1.4.1 Hydrogen is lighter than air and any Jeak goes
might form part of an electrical circuit.
up the atmosphere readily. It shall be stored in gas tight
containers either in atmospheric condition or under 7.2.2.7 Do not remove protection cap unless ready to
pressure. withdraw hydrogen from the cylinder. Appropriate and
standard valves must be used. Explosive gas check of
7.1.4.2 Storage area should be protected by fire
valves and fittings should be done before usage.
hydrants and automatic sprinklers for extinguishing a
fire. 7.2.2.8 Use only standard colour code (Red colour
without any band) for hydrogen cylinders (see IS 4379).
7.1.4.3 The storage tanks shall be designed as per
standard code. 7.2.2.9 Cylinders for hydrogen, whether full or empty
should never be used as rollers for moving heavy or
7.1.4.4 Each storage tank shall be equipped "vith relief bulky articles.
valves. Vent pipes from the valves should terminate
to
upward and should have a flame arrestor. Suitable 7.2.2. No one should tamper with numbers,
markings, or test dates stamped on cylinders.
provision should be made to prevent anything from
entering the vents. A drain should also be arranged at 7.2.2.11 When the cylinder is empty, disconnect it,
the bottom of the vent pipe. Any discharge through the insert the valve plug and replace the cylinder protective
relief valves should not enter work area or contact cap.
source of ignition.
7.2.2.12 Store empty cylinders separate from filled
7.2 Handling cylinders and fasten an 'EMPTY' tag on cylinders
immediately upon emptying. Close valve, replace plug
7.2. t General
or nut on valve outlet and secure valve protecting cap
7.2.1.1 Hydrogen should be handled wearing an snugly.
approved respirator, chemical resistant gloves and
7.3 Lahelling
safety goggles and other protective clothing (see 6).
a) Any vessel containing hydrogen should carry an
7.2.1.2 Sources of ignition such as smoking and open identifying label or stencil.
flames are prohibited where hydrogen is handled. b) Label should be as per rules and regulations.
c) Each cylinder must be labelled with
7.2.1.3 Safety recommendations and safe operating
'FLAMMABLE GAS' 'CLASS 2'.
procedures should be strictly followed by the persons
handling hydrogen. 7.4 Transportation
7.2.2 Handling of Cylinders 7.4.t Labelling
7.2.2.1 Before filling the cylinder with hydrogen, Labels : Class 2 labels must be displayed on the
check and confinn for its validity. It shall have valid transport vehicle:
test certificate from the concerned authorities. Cylinder a) Compressed gas : UN No. 1049, and
must be hydraulically tested before filling hydrogen
b) Refrigerated liquid : UN No. 1966.
gas. Both seBer and consumer must verify that the
period of date of testing is still valid. 7.4.2 Pre-departure Check':> for Vehicles Carrying
Hydrogen in Cylinders in Manifold Systems Mounted
7.2.2.2 Cylinders should never be subjected to rough on Trucks
handling or to abnormal mechanical shock such as
7.4.2.1 Prior to and after loading, the drivers must take
dropping, bumping, dragging or sliding. They should
a complete inspection of the vehicle to ensure that it
always be kept in vertical position.
meets all performance safety requirements and is
7.2.2.3 Ropes, slings, hooks, tongs and similar handling roadworthy for transporting hydrogen. A few of the
devices which may produce sparks or static electricity numerous items that are checked are the lights, lyres,
should not be used during handling ~md use of hydrogen suspensions and brakes.
cylinder.
7.4.2.2 The driver should maintain a log entry book
7.2.2.4 A suitable hand truck, fork truck or similar for critical parameters like pressure, etc, during transit.
device to which the cylinders can be firmly secured
7.4.2.3 Ensure availability of fire extinguishers
should be used for transporting the cylinders. ( DCP/carbon dioxide J all the vehicle.
3
IS t 520t : 2002
7.4.2.4 Ensure availability of emergency kit on the 8.1.2 If spills or leaks of hydrogen occur, only properly
vehicle. protected personnel should remain in the area and entry
to' others should be restricted.
7.4.2.5 Ensure availability of transport emergency
(TREM) card and instruction manual during 8.1.3 Every organization handling hydrogen must fonn
transportation on the vehicle. an cmergency response team, which is available round
the clock. Spills or leaks should be handled by the
7.4.3 During Transportation
emergenCy response team specially trained to handle
7.4.3.1 Do not smoke in the cabin. All sources of emergency situations.
ignition must be kept away from the truck during
8.1.4 If spills or leaks develop, take measures to hasten
tr::msportation.
the dissipation of harmful vapours.
7.4.3.2 Driver should follow specified route only,
8.1.5 In case of a major spill or equipment rupture, the
maintain speed limit, never park the truck near
exposed area should be evacuated and unprotected
residential areas, drive truck carefully and observe all
personnel must not re-enter the area unless declared
rules and signals, avoid overtaking of moving vehicles
safe.
and do not leave the truck without watch at any time.
8.1.6 Proper respiratory protection should be provided
7.4.3.3 No repairs involving gas cutting, welding, etc,
for use by personnel entering the area for tests
should be done during transportation period. Ifr equired
or to repair damaged equipment as high hydrogen
at all, repairs should be done by authorized and
concentration may exist.
competent personnel of maintenance department/plant
who arc deputed by manufacturer/supplier. 8.1. 7 Stop flow of gas/shut off leak, if it can be done
without risk.
7.4.3.4 The driver should physically inspect complete
mounting periodically and immediately report any 8.1.8 If source of a leak is a cylinder and the leak cannot
abnormality to the supplier. be stopped in place, remove the leaking cylinder to a
safe place in the open air, and repair leak or allow the
7.4.3.5 Jn case of emergency ( for example leaks, fires,
cylinder to empty.
accident, etc) follow the instructions mentioned in the
'lnstmction manual during transportation' to control 8.1.9 In both gas or liquid spills, remove all ignition
and mitigate an emergency. Immediately contact sources.
manufacturer/supplier, police, RTO, fire brigade and
8.2 Evacuation
other local authorities.
If the release is not contained in an appropriate device
7.4.4 Drivers Training
or' system, all personnel not appropriately protected
7.4A.1 The basics of any effective safety programme must evacuate the contaminated spaces. Evacuation
ror transportation of hydrogen is adequate training. of additional areas should be considered as a precaution
against the spread of the release or subsequent explosion
7.4.4.2 Each driver must be carefully selected and
or fire.
receive adequate amollnt of classroom training, audio
visual instructions and job training. The training 8.3 Waste Disposal
must be done at certified regional training institutes.
To be burnt under control condition.
Management must personally qualify each driver
before he is allowed to deliver hydrogen. 9 FIRE PREVENTION AND FIRE FIGHTING
7.4.4.3 Systematic training/retraining and reviews must 9.1 General
be carried out to ensure that proficiency is maintained.
Hydrogen is highly flammable. Hydrogen flame is
Drivcrs must be trained in the following:
almost invisible and can cause severe explosions. It is
a) Safe driving methods;
easily ignited with many sources of energy, some of
b) Actions to be taken during emergency~ which are listed below:
c) Proper use of fire extinguishers, emergency kits, a) Open flames;
TREM cards, instmction manuals, etc~ and b) Electrical equipments~
d) Communication with manufacturer/supplier.
c) Electrostatic sparks~
8 SPILLAGE, LEAKAGE AND WASTE d) Sparks from striking objects~
DISPOSAL e) Friction;
t) Thermite sparks;
8.1 Spillagc/Lcal{agcs
g) Air or oxygen, other oxidants~
8.1.1 Frequent inspections of equipment, containers h) Hot surfaces;
and vessels containing hydrogen should be made to j) Hot hydrogen leaking into ambient air; 3:nd
detect or prevent leaks. k) Catalytic surfaces.
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IS 15201 : 2002
9.2 Fi"e Prevention b) Site safety regulations,
c) Emergency response procedures (leaks/spi 11s1
9.2.1 Minimize all potential sources ofleaks.
evacuation),
9.2.2 Eliminate as far as possible all sources of ignition. d) Use of fire fighting equipment,
e) Use of protective clothing/apparatus including
9.2.3 Make provision for isolation of hydrogen, means
breathing sets where required,
of escape and methods of controlling any fire.
f) First aid, and
9.2.4 Adequate meallS of detecting fire and hriving early g) Rescue operations.
warning, alarms in the event of fire shall be provided.
10.1.3 In addition, individuals shall receive specific
9.2.5 Fmergency Re,'ponse Procedures and Systems training in the activities for which they arc employed.
Refresher courses should be arranged on a periodic
9.2.5.1 Full emergency procedures and systems shall
basis. Older employees should be re-educated.
be established and periodic mock drills should be
carried out. 10.1.4 Each employee should know the location and
correct operation of gas and fire alarm systems,
9.2.5.2 The emergency response team must be well
sprinklers, monitors and other fire fighting equipment
trained with respect to 'Do's' and 'Don'ts', standard
They should know the location of safety showers, eye
operating procedures (SOP), mitigation systems and
washes and first aid boxes.
hazards of hydrogen handling.
10.2 Health Monitoring
9.3 Fire Fighting
10.2.1 Personal Hygiene
9.3.1 For Spills rVhich have not Ignited
Employees should t.ake a bath daily after finishing work.
If a spill has not ignited. use water spray to direct
Eating, drinking or storing offood should be prohibited
flammable gas--'air mixtures away from sources of
ncar the place where hydrogen is handled.
ignitjon.
10.2.2 Physical Examination
9.3.2 For ."pills Which have Ignited
10.2.2.1 Preplacement physical examinations
9.3.2.1 Hydrogen flame is almost invisible. Therefore
proper care should be taken while approaching any Proper preplacement medical examinations of a
names for fire fighting. personnel should be carried out to determine the,
physical fitness before assigning the job.
9.3.2.2 Stop flow of the gas, if-possible.
10.2.2.2 Periodic examination
9.3.2.3 Because of danger ofre-ignition, hydrogen fires
normally should not be extinguished until the supply Annual medical examination should be carried out as
of hydrogen has been shut off. Flashback along trail required by laws/regulations (Factories ActlS'tate
may occur. Factories Rules).
9.3.2.4 If the flow cannot be stopped, allow the contents 11 FIRST AID AND MEDICAL TREATMENT
of the cylinder to burn under control.
It.l General Principles
9.3.2.5 If liquid hydrogen has ignited, use water to
keep fire exposed containers cool and to protect men First aid treatment should be started at once in all cases
trying to stop the source of a spill. of contact with hydrogen in any form or injury may
result. Refer all injured persons to a physician even
10 TRAINING AND HEALTH MONITORING when the injury appears to be slight. Give the physician
a detailed account of the accident.
10.1 Training
11.2 First Aid Tre. . tment
W. 1. t All personnel engaged in the operation,
rnai ntenancc and attending emergency of hydrogen and 11.2.t Inhalation /
related systems shall receive training suitable for the
\York on which they are engaged. Inhalation of hydrogen gas causes asphyxiation.
Remove the affected person from exposurel
tn.1.2 Training shall be arranged to cover all the contamination area. Place him in the recovery position
aspects and potential hazards that the particular operator as necessary. If breathing has stopped begin rescue
is likely to encounter. Training shall cover the breathing. If heart action has stopped begin CPR.
following areas: If medical oxygen and trained personnel are available,
a) The potential hazards of hydrogen, administer oxygen to the affected person. If UIl-
5
IS 15201 : 2002
conscious, do not give anything to drink. If conscious 11.2.3 Eyes
make the affected person lie or sit down quietly.
Treat for frost bite.
11.2.2 Skin Contact With Liquid Hydrogen
11.2.4 Antidote/Dosages
Treat for frost bile. Soak the affected part in luke warm
water. Seek medical attention. No specific antidote is available.
ANNEX A
( Foreword)
COMMITTEE COMPOSITION
Industrial Safety and Chemical Hazards Sectional Committee, CHD 8
Organization Representative(s)
National Safety Council, Mumbai SHRI K.C. GUPTA (Chairman)
Airports Authority of India, New Delhi REPRESENTATIVE
Atomic Energy Regulatory Board, Mumbai SHRI P. K. GHOSH
Bhabha Atomic Research Centre, Mumbai DR B. N. RATHI
Celltral noiler Board. New Delhi REPRESENTATIVE
Century Rayon, Thane SHRI H. G. UITAMCHANDANI
SHRI S. K. MISHRA (Alternate)
Central Lcather Research Institute, Chennai REPRESENTATIVE
Central Mining Research Institute, Jharkhand SHRI J. K. PANDEY
Central Warehousing Corporation, New Delhi REPRESENT A l,vE
Conll:deration of Indian Industries, New Delhi REPRESENTAn VE
Department of Explosives, Nagpur REPRESENTATIVE
Deparlrnent of Industrial Policy and Promotion, DR D. R. CHAWLA
Nl:w Delhi
Dcvciopml!nl Commissioner (SSI), New Delhi REPRESENTATIVE
Directorate General of Health Services, New Delhi REPRESENT ATIVE
Directorate General Factory Advice Service and DR A. K. MAJUMDAR
Labour Institutes, Mumbai SHRI S. P. RANA (Alternate)
Directorate of Industrial Safety and Health, REPRESENT A TI VE
(Factory Inspectorate). Mumbai
Din:ctorate General of Mines Safety, Dhanbad DIRECTOR OF MINES SAFETY (MSE)
DEPUTY DIRECTOR OF MINES SAFETY
(HQ) (Alternate)
EmrloYl.:es State Insurance Corporation, New Delhi
Exccllnllllslrics Limited, Mumbai REPRESENTATIVE
Ilindustan Aeronautics Limited, Bangalore REPRESENTATIVE
Hindustan Lever Limited, Mumbai SHRI B. B. DAVE
SHRI ADITYA JUAVAR (Alternate)
Indian Instituk of Chemical Technology, Hyderabad SHRI S. VENKATESWARA RAo
Illliian Chemical Manufacturers Association, Mumbai SHRI V. N. DAS
SHRI A. A. PANJWANI (Alternate)
Indian Drugs and Pharmaceuticals Limited, Rishikesh REPRESENTATIVE
Indian Petrochemical Corporation Limited, Vadodara SHRI P. VUAYRAGHAVAN
SHRI M. R. PATEL (Allernate I)
SIIRI A. V. SAMTHY (Alternate II)
Indian Span: Research Organization, Sriharikota SHRI P. N. SAN KARAN
SIIRI V. K. SRIVASTAVA (Alternate)
Industrial Toxicology Research Centre, Lucknow Dr VI RENDRA MISRA
Dr V. P. SHARMA (Alternate)
Ministry of Defence (DGQA), New Delhi SWI,l M. S. SULTANIA
SHRI SUJIT GHOSH (Alternate)
(Continued on page 7)
6